Blind Assembly Fastener System

ABSTRACT

Disclosed are systems and methods for coupling a first panel to a second panel via a fastening system. The fastening system comprises fastener, a doghouse structure, and a seal assembly. The fastener includes a head assembly coupled to a collar. The head assembly is configured to engage a doghouse structure positioned on the first panel and the collar is configured to pass through and to retain the second panel via an opening formed in the second panel. The seal assembly includes a seal and a seal carrier. The seal carrier is coupled to the fastener via a frangible connection.

CROSS-REFERENCE

The present application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 63/022,612, filed May 11, 2020, and entitled “Blind Assembly, Close-Panel, Doghouse Interface Fastener System,” and U.S. Provisional Patent Application Ser. No. 63/056,854, filed Jul. 27, 2020, and entitled “Readyset Seal,” the contents of which are hereby incorporated by reference.

BACKGROUND

Automotive components require fastening techniques that are simple to manufacture and assemble. Further, fastening techniques should above all be reliable and efficient. A blind, close-panel assembly is a condition where the fastening is focused between the panels being fastened to each other (such as automotive panels or other components), while trying to keep those same panels positioned very closely to each other.

Typical fastening solutions that allow this type of closely-positioned assembly include, magnets, adhesive tape, and mechanical fasteners. For example, a metal fastener can be used to make a blind connection between panels. Traditionally, a simple metal fastener can be received within an opening (e.g., a window or aperture) formed in a primary panel and configured to engage a blade structure that extends from an undersurface of a secondary panel. Existing metal fasteners are deficient in that the abrasive nature of the metal fasteners often wears through the paint or anticorrosive coatings of the primary panel (e.g., the sheet metal framework of a vehicle), thereby promoting corrosion. In addition, metal fasteners have a tendency to buzz, squeak, and rattle, a condition typically referred to as “BSR.”

In an effort to mitigate BSR and to prevent corrosion, plastic fasteners can be used as a replacement for metal fasteners. Such plastic fasteners, however, can increase the distance between panels and sometimes require moderately high insertion forces. In some examples, fasteners are fabricated using a combination of metal and plastic components to mitigate abrasion and avoid BSR. Such fasteners, however, are typically larger and can be more difficult to manufacture. Further, while fasteners come in many sizes and levels of performance, many fastener types cannot utilize a blade structure for blind part-in-assembly (PIA) strategies.

It would therefore be highly desirable to have a fastener assembly with improved assembly characteristics that provides reliable and secure fastening, while allowing for the panels to be positioned very closely to each other.

SUMMARY

The present disclosure relates generally to a fastening system to form a blind connection between the panels, such as automotive panels, substantially as illustrated by and described in connection with at least one of the figures, as set forth more completely in the claims.

DRAWINGS

The foregoing and other objects, features, and advantages of the devices, systems, and methods described herein will be apparent from the following description of particular examples thereof, as illustrated in the accompanying figures; where like or similar reference numbers refer to like or similar structures. The figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the devices, systems, and methods described herein.

FIGS. 1a through 1d illustrate side views of example fastening systems configured to form a blind connection between panels in accordance with aspects of this disclosure.

FIG. 2a illustrates a perspective assembly view of the pass-through doghouse-based fastening system of FIG. 1d in accordance with aspects of this disclosure.

FIGS. 2b and 2c illustrate, respectively, partially assembled and assembled perspective views of the pass-through doghouse-based fastening system of FIG. 2 a.

FIGS. 3a through 3d illustrate, respectively, a push pin fastener, a pin and grommet (P&G) fastener, a box-prong fastener, and a specialty fastener for use with a pass-through doghouse-based fastening system.

FIGS. 4a and 4b illustrate an example pass-through doghouse-based fastening system configured with ribs in accordance with aspects of this disclosure.

FIGS. 5a and 5b illustrate an example pass-through doghouse-based fastening system configured with ribs and wings in accordance with aspects of this disclosure.

FIGS. 6a through 6d illustrate an example pass-through doghouse-based fastening system configured in accordance with another aspect of this disclosure.

FIG. 7 is a flowchart representative of an example a method of coupling a first panel to a second panel using the fastener of FIGS. 2a through 2 c.

FIGS. 8a and 8b illustrate, respectively, perspective and bottom plan views of a fastener with a seal assembly in accordance with an aspect of this disclosure.

FIG. 8c illustrates a side view of the fastener of FIG. 8a with the seal assembly assembled between panels.

FIGS. 9a through 9f illustrate perspective assembly views of the pass-through doghouse-based fastening system with a seal assembly during assembly in accordance with an aspect of this disclosure.

FIG. 10 is a flowchart representative of an example a method of coupling a first panel to a second panel using the fastener with a seal assembly of FIGS. 7a through 7 c.

FIG. 11 is a flowchart representative of an example a method of manufacturing a fastening system with a fastener and a seal assembly.

DESCRIPTION

References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within and/or including the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. In the following description, it is understood that terms such as “first,” “second,” “top,” “bottom,” “side,” “front,” “back,” and the like are words of convenience and are not to be construed as limiting terms. For example, while in some examples a first side is located adjacent or near a second side, the terms “first side” and “second side” do not imply any specific order in which the sides are ordered.

The terms “about,” “approximately,” “substantially,” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the disclosure. The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the disclosed examples and does not pose a limitation on the scope of the disclosure. The terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the disclosed examples.

The term “and/or” means any one or more of the items in the list joined by “and/or.” As an example, “x and/or y” means any element of the three-element set {(x), (y), (x, y)}. In other words, “x and/or y” means “one or both of x and y”. As another example, “x, y, and/or z” means any element of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, “x, y, and/or z” means “one or more of x, y, and z.”

A fastener can be used to form a blind connection between a first panel and a second panel, such as automotive panels. In one example, a fastening system for forming a sealed blind connection between a first panel and a second panel comprises: a fastener configured to retain the second panel via an opening formed in the second panel, wherein the fastener comprises a head assembly configured to engage a doghouse structure positioned on the first panel; and a seal assembly having a seal and a seal carrier, wherein the seal carrier is coupled to the fastener via a transitory connection. In some examples, the transitory connection is an adhesive, a frangible connection, and/or a mechanical coupling. In some examples, the fastener and the seal carrier are fabricated as a single component. The fastener and the seal carrier may be fabricated via a plastic injection process. For example, the transitory connection may be a flash-gate formed during the plastic injection process. In some examples, the seal carrier is a rigid plastic structure and the seal is over-molded onto the seal carrier. In some examples, the seal carrier is configured to transition from an initial position to a deployed position by breaking the transitory connection. The seal carrier may be configured to engage a feature of the fastener to secure the seal carrier in the deployed position. The seal carrier may be configured to surround the doghouse structure when in the deployed position. In some examples, the doghouse structure is configured to pass at least partially through the opening.

In another example, a method of forming a sealed blind connection between a first panel and a second panel via a doghouse structure and a fastener that has a head assembly and a seal assembly comprises: sliding the head assembly across a surface of the first panel into a chamber of the doghouse structure; sliding the seal assembly from an initial position to a deployed position, wherein the seal assembly comprises a seal and a seal carrier; and passing a portion of the fastener through an opening formed on the second panel. In some examples, the initial position is at or adjacent a collar of the fastener and the deployed position is at or adjacent the head assembly. In some examples, the seal carrier is coupled to the fastener in the initial position via a transitory connection. In some examples, the transitory connection is a flash-gate formed during a plastic injection process.

In yet another example, a method of manufacturing a fastening system comprises: forming a fastener via a plastic injection process, wherein the fastener defines a head assembly, a neck, and a seal carrier, wherein the seal carrier is coupled to the neck by a transitory connection; and over-molding a seal on to the seal carrier. In some examples, the transitory connection is a flash-gate formed during the plastic injection process. In some examples, the seal carrier is coupled to the neck via a collar. In some examples, the seal carrier is configured to separate from the neck via the transitory connection and to deploy to the head assembly.

FIGS. 1a through 1d illustrate side views of example fastening systems 100 a, 100 b, 100 c, 100 d configured to form a blind connection between a first panel 102 and a second panel 104. The first panel 102 and the second panel 104 may be, for example, automotive panels. Depending on the application, the first panel 102 and the second panel 104 may be fabricated from, for example, metal (or a metal alloy), synthetic or semi-synthetic polymers (e.g., plastics, such as acrylonitrile butadiene styrene (ABS) and polyvinyl chloride (PVC), etc.), composite materials (e.g., fiber glass), or a combination thereof. In one example, the first panel 102 is an automotive secondary panel and the second panel 104 is an automotive primary panel. In the automotive industry, example first panels 102 include, without limitation, door trim panels, moldings, trim pieces, and other substrates (whether used as interior or exterior surfaces).

The first panel 102 may define an A-surface 102 a and a B-surface 102 b (illustrated as an undersurface). The A-surface 102 a, also called a class A surface, is typically the surface that is visible after assembly and, for that reason, is more aesthetically pleasing (e.g., textured, coated, or otherwise decorated) and typically free of attachment devices and/or related features. Conversely, the B-surface 102 b, also called a class B surface, is typically the surface that is not visible after assembly and typically includes various attachment devices and/or related features.

The first panel 102 may be include, define, or otherwise be associated with attachment devices and/or related features, such as one or more towers 108, doghouse structure 106, etc. Depending on the material type, the attachment devices and/or related features may be formed on the B-surface 102 b during molding or layup of the first panel 102, or attached after fabrication (e.g., using adhesive or mechanical fasteners). After assembly, the second panel 104 is covered at least partially by the first panel 102. The second panel 104 may be, for example, a structural component of a vehicle, such as doors, pillars (e.g., an A-pillar, B-pillar, C-pillar, etc.), dashboard components (e.g., a cross member, bracket, frame, etc.), seat frames, center consoles, fenders, sheet metal framework, or the like.

FIG. 1a illustrates a clip-based fastening system 100 a configured to couple the first panel 102 to the second panel 104. As illustrated, the first panel 102 may include one or more towers 108 that protrude from the B-surface 102 b. Each tower 108 (sometimes called a bezel or protrusion) may be shaped as a blade or planar tab, for example. To form the blind connection between the first panel 102 and the second panel 104, the fastener 112 and the tower 108 are inserted into an opening 110 formed in or on a surface of the second panel 104. In some examples, the fastener 112 may be pre-attached to either the tower 108 or the opening 110 to define a part-in-assembly (PIA). The tower 108 of the first panel 102 is inserted into a channel formed by the fastener 112 to, in effect, lock the fastener 112 in place within the opening 110, thus securing the first panel 102 and the second panel 104 to one another. The clip-based fastening system 100 a eliminates rib setup variation and allows for a relatively close assembled distance (D₁) between the first and second panels 102, 104. A clip-based fastening system 100 a provides a blind PIA solution that positions the second panel 104 closely to the first panel 102 since the tower 108 can pass through the opening 110 in the second panel 104 to the B-side. Both the length of the fastener 112 and the length of the tower 108 determine the protrusion distance (P₁) on the B-side.

FIG. 1b illustrates a doghouse-based fastening system 100 b configured to couple the first panel 102 to the second panel 104. As illustrated, the first panel 102 may include one or more doghouse structures 106 that protrude from the B-surface 102 b. A doghouse structure 106 allows for the first panel 102 to be used with a wide variety of fasteners 112, such as W-type fasteners, push pin fasteners, etc. For example, a variety of different fasteners 112 may be designed with a common head assembly that is sized and shaped to engage the doghouse structure 106, thus enabling interchangeability of the fasteners 112.

A fastener 112 is coupled to the doghouse structure 106 and configured to pass at least partially through the opening 110 and engage the second panel 104. As illustrated, the doghouse structures 106 increases the assembled distance (D₂) between the first and second panels 102, 104. Thus, a doghouse-based fastening system 100 b can introduce a barrier to achieving close-panel, blind PIA fastening because the doghouse structure 106 occupies space between the first and second panels 102, 104. As illustrated, the protrusion distance (P₂) through the B-side of the second panel 104 is dictated by the on the length of the fastener 112. Therefore, a shorter fastener 112 may be employed to reduce the protrusion distance (P₂).

FIG. 1c illustrates a second doghouse-based fastening system 100 c configured to couple the first panel 102 to the second panel 104. As explained in connection with FIG. 1b , the doghouse structure 106 can result in a larger assembled distance (D₃). To reduce the assembled distance, the second panel 104 may be shaped with a recessed panel 114 to accommodate the doghouse structure 106. By using a recessed panel 114 with a doghouse structure 106, the first and second panels 102, 104 can be positioned much closer together to achieve a smaller assembled distance (D₃). The recessed panel 114, however, must be large enough to house the doghouse structure 106. In some cases, a large recessed panel 114 may negatively impact the overall assembly performance and/or appearance of the second panel 104. Further, the recessed panel 114 increases the protrusion distance (P₃) through the B-side of the second panel 104, thus decreasing useable space on the B-side of the second panel 104.

FIG. 1d illustrates a pass-through doghouse-based fastening system 100 d configured to couple the first panel 102 to the second panel 104, while minimizing both the assembled distance (D₄) between the first and second panels 102, 104 and the protrusion distance (P₄) through the B-side of the second panel 104. The pass-through doghouse-based fastening system 100 d uses a smaller doghouse structure 106 that is configured pass at least partially through the opening 110 in the second panel 104, thus achieving a small assembled distance (D₄) that is comparable to the assembled distance (D₃) of FIG. 1c , but without necessitating the recessed panel 114.

FIGS. 2a through 2c illustrate an example pass-through doghouse-based fastening system 100 d. Specifically, FIG. 2a illustrates a perspective assembly view of the example pass-through doghouse-based fastening system 100 d of FIG. 1d , while FIGS. 2b and 2c illustrate, respectively, partially assembled and assembled perspective views thereof.

While a blind connection will be described primarily, it is to be understood, however, that the present fastening system may be adapted for use with structures other than the illustrated first and second panel 102, 104 that do not require the blind connection described. Accordingly, the present fastening system is not to be limited to only blind connections. Further, while only a single doghouse structure 106 and a single opening 110 are illustrated in the examples, it should be appreciated that a given first panel 102 may include multiple doghouse structures 106 and the second panel 104 may include multiple openings 110, depending on the number of fastener points to be used between the first and second panels 102, 104. In used, the head assembly 210 slides into the doghouse structure 106 as indicated by the first arrow 202 to form a PIA. Once in place, the fastener 112 may be inserted into the opening 110 of the second panel 104 as indicated by the second arrow 204.

The fastener 112 generally comprises a head assembly 210, a neck 212, a collar 214, and one or more retention features 216. The head assembly 210 is configured to engage a doghouse structure 106 of the first panel 102. The neck 212, which couples the head assembly 210 to the collar 214, is typically narrower than the head assembly 210 and the collar 214. The collar 214 is configured to enter and engage (or otherwise retain) the second panel 104 via, for example, the opening 110. As can be appreciated, a portion of the neck 212 may also pass through the opening 110. The collar 214 may be secured within the opening 110 via one or more retention features 216, which may be outwardly biased legs coupled to the collar 214. In some examples, the collar 214 may be omitted, in which case the retention features 216 may be coupled directly to the neck 212. The retention features 216 may include a return arm 216 a resiliently connected to the collar 214 that deflects as an end of the fastener 112 is inserted into an opening 110 of the second panel 104. A catch 216 b (e.g., a ledge, lip, etc.) may be coupled to a distal end of the return arm 216 a to engage the second panel 104 (e.g., at the perimeter of the opening 110). The retention features 216 are relatively rigid towards outward forces and as such will lock the collar 214 (or neck 212) into place within the second panel 104 once it has passed through the opening 110. Additionally, the fastener 112 may be configured to engage one or more features of the second panel 104.

The fastener 112 may be fabricated in various sizes depending on the application. The illustrated fastener 112 can be described as a “W-type” fastener because it generally resembles a “W” when viewed from a side, as best illustrated in FIGS. 1b through 1d . A W-type fastener provides lead-in features for finding the opening 110. While the fastener 112 is generally described and illustrated as a W-type fastener, as will be discussed in connection with FIGS. 3a through 3 d, the fastener 112 may adopt other types of fasteners for use with the pass-through doghouse-based fastening system 100 d.

The opening 110 can be generally rectangular and define a size and shape that is complementary to that of the fastener 112 such that the fastener 112 can be inserted and retained therein. However, openings 110 of other shapes are contemplated. Therefore, the opening 110 may be rectangular, rounded rectangular (e.g., a stadium), circular (FIGS. 6a to 6d ), oval, or any other suitable shape.

As illustrated, the second panel 104 is sized and shaped to define the at the doghouse structure 106. The doghouse structure 106 acts as a receptacle for a head assembly 210 of the fastener 112. It is desirable to insert the head assembly 210 of the fasteners 112 into the chamber 218 and retain it therein. As illustrated, the doghouse structure 106 is composed of a set of doghouse sidewalls 220 defining a chamber 218 therebetween. The doghouse sidewalls 220 may include one or more features shaped to increase engagement with the head assembly 210, such as interference features 222. In some examples, the interference features 222 may exhibit a soft click as the fastener 112 is secured in the chamber 218. The doghouse structure 106 provides a clear pathway from one or more insertion openings to the chamber 218. In the illustrated example, the fastener 112 would be able to slide into the chamber 218 of the doghouse structure 106 from one of two insertion openings. For example, the fastener 112 would be able to slide as illustrated by arrow 202 or in the opposite direction. It is contemplated that the doghouse structure 106 may be molded during molding of the first panel 102; however, in some examples, they may be fabricated separated and joined to one another (e.g., using adhesive, mechanical fasteners, etc.).

The doghouse structure 106 is contemplated to be modified in size and shape to suit individual applications. For example, while illustrated with two opposing doghouse sidewalls 220, in some examples, the doghouse structure 106 may further include a doghouse endwall formed to bridge the gap between the set of doghouse sidewalls 220, thereby walling off three of the four sides of the chamber 218. In this example, the fastener 112 would only be able to slide into the chamber 218 of the doghouse structure 106 from a single insertion opening, but would be restricted in movement at three sides.

As will become apparent, it is sometimes useful to assemble the first panel 102 and the second panel 104 by first inserting the fastener 112 into the doghouse structure 106 of the first panel 102 (as indicated by the first arrow 202) to form a PIA and then subsequently inserting fastener 112 of the PIA into an opening 110 of the second panel 104 (as indicated by the second arrow 204). In some examples, to assemble a pass-through doghouse-based fastening system 100 d, the head assembly 210 of the fastener 112 is slid laterally across a surface of the first panel 102 into the chamber 218 until fastener 112 stops (e.g., against a wall) or is otherwise aligned between the doghouse sidewalls 220. In some examples, the fastener 112 is held in place by interference features 222, which may exhibit a soft click as the fastener 112 is secured in the chamber 218. The fastener 112, now a PIA component with the first panel 102 (FIG. 2b ), may be shipped to a customer (e.g., an original equipment manufacturer (OEM)). The OEM may then assemble the PIA component with a second panel (e.g., a vehicle panel) via all the fasteners 112 coupled thereto as illustrated in FIG. 2 c.

The doghouse structure 106 can make the head assembly 210 of the fastener 112 positionally located in a fixed manner or, if desired, to provide the fastener 112 with some linear freedom (e.g., float) to move within the chamber 218. While a smaller doghouse can limit the positional float of the head assembly 210 within the chamber 218, positional freedom requirements can be accomplished via the opening 110. Therefore, the pass-through doghouse-based fastening system 100 d enables the doghouse structure 106 to directly interact with the opening 110 to allow fasteners 112, such as W-type fasteners, to be part of a datum or locating solution.

The opening 110 may be sized to provide a desired amount of longitudinal movement 208 a and/or lateral movement 208 b. In some examples, the pass-through doghouse-based fastening system 100 d may be configured to accommodate 2-way assembly tolerance or float (e.g., for thermal growth) in the longitudinal direction (length) of the opening 110. The tolerance in the longitudinal direction may be, for example, about ±1 mm to ±5 mm, or about ±3 mm. In other examples, a 4-way version of the pass-through doghouse-based fastening system 100 d is contemplated with tolerance in the lateral direction (width) as well as the longitudinal direction. The tolerance in the longitudinal direction may be, for example, about 1 mm to ±3 mm, or about ±1 mm. In some examples, the lateral direction tolerance is less than the longitudinal direction tolerance, yielding an asymmetrical tolerance or float solution (e.g., the longitudinal direction tolerance may be ±3 mm, while the lateral direction tolerance may be ±1 mm). For example, as best illustrated in FIG. 2c , the opening 110 may be lengthened along its longitudinal axis to define movement gaps 206 that allow for longitudinal movement 208 a. The amount of lateral direction tolerance is dictated by the type of fastener 112 used. For example, the width of the opening 110 cannot be wider than the width of the retention features 216 when the expanded since the catch 216 b would need to engage a portion of the opening 110. In some examples, the opening 110 may be sized to provide minimal longitudinal movement 208 a and/or lateral movement 208 b, for example, with an assembly clearance of about ±0.25 mm.

Those of skill in the art would appreciate that the principles of the pass-through doghouse-based fastening system 100 d may be used with various types of fasteners 112, provided that the head assembly 210 is configured to engage the doghouse structure 106.

An end of the fastener 112 (e.g., the neck 212 and/or the collar 214) may be shaped as any desired type of fastener 112. FIGS. 3a through 3d illustrate, respectively, a push pin fastener 112 a, a pin and grommet (P&G) fastener 112 b, a box-prong fastener 112 c, and a specialty fastener 112 d (e.g., a CenterLok™ fastener, which is available from Deltar®). As illustrated in FIG. 3a , the push pin fastener 112 a (sometimes called trees, pine trees, Christmas trees, etc.) includes a plurality of barbs or teeth along its length. With reference to FIG. 3b , the P&G fastener 112 b is a reusable two-piece fastener having a low insertion value. The P&G fastener 112 b may be a single position fastener or a multi-position fastener. Each of the aforementioned fasteners can include a head assembly 210 is configured to engage the doghouse structure 106 and used in lieu of a W-type fastener to fasten components and panels very closely to one other, while still using a doghouse structure 106. In some examples, as illustrated in FIG. 3c , the pass-through doghouse-based fastening system 100 d may comprises a seal 302 positioned between the first and second panels 102, 104. For example, a seal 302 may be used where it is desirable to mitigate dust, dirt, and/or moisture penetration through the opening 110. The seal 302 may be embodied as a ring (e.g., an annulus) and fabricate from foam material, thermoplastic, rubber, etc. For example, as illustrated, a seal 302 can be configured to surround the doghouse structure 106 between the first panel 102 and the second panel 104. In some examples, the pass-through doghouse-based fastening system 100 d may include additional features, such as ribs and wings.

FIGS. 4a and 4b illustrate example pass-through doghouse-based fastening system 100 d configured with ribs 402. When assembled, the ribs 402 reside between the first and second panels 102, 104 at an interface between the doghouse structure 106 and the first panel 102. The ribs 402 serve as a buttress to increase the strength and support of the doghouse structure 106 (e.g., the doghouse sidewalls 220), while also controlling over-travel, where desired or required. Therefore, in some examples, the fastener 112 comprises one or more ribs 402 configured to support the doghouse structure 106 and to control over-travel.

FIGS. 5a and 5b illustrate example pass-through doghouse-based fastening system 100 d configured with ribs 402 and wings 502. The wings 502, which may be flexible, help control over-travel and mitigate BSR. When assembled, the ribs 402 and wings 502 reside between the first and second panels 102, 104. As illustrated, the wings 502 are coupled to the head assembly 210 (e.g., near the retention features 216) and biased to push against the second panel 104 once assembled, effectively serving as a spring between the first and second panels 102, 104 to absorb movement between the first panel and the second panel.

While the doghouse structure 106 is illustrated as generally rectangular, other shapes are contemplated, including other quadrilaterals (e.g., square) and rounded shapes (e.g., circles and ovals). For examples, FIGS. 6a through 6d illustrate an example pass-through doghouse-based fastening system with a generally circular doghouse structure 602 and a fastener 112 (again illustrated as a W-type fastener). As with the pass-through doghouse-based fastening systems of FIGS. 2a through 2 c, the doghouse structure 602 comprises a set of doghouse sidewalls 220; however, the doghouse sidewalls 220 are shaped to define a generally circular outer perimeter.

FIG. 7 is a flowchart representative of an example method 700 of coupling a first panel 102 to a second panel 104 using a pass-through doghouse-based fastening system having a doghouse structure 106 and a fastener 112. The fastener 112 has a head assembly 210 and a neck 212. At step 702, the head assembly 210 slides across a surface of the first panel 102 into a chamber 218 of the doghouse structure 106. At step 704, at least a portion of the neck 212 and/or the collar 214 passes through an opening 110 formed on the second panel 104. The neck 212 and/or the collar 214 is configured to engage the second panel 104 via a retention feature 216. In some examples, the retention feature 216 includes a return arm 216 a resiliently connected to a collar 214 that is coupled to a collar 214 and configured to deflect as the collar 214 is passed through the opening 110. As mentioned above, in some examples the retention features 216 are coupled to the neck 212 and a collar 214 is omitted. At step 706, passing at least a portion of the doghouse structure 106 through the opening 110.

As noted above, it is sometimes advantageous to seal the fastener, thereby preventing dirt, dust, and/or liquid from passing through the second panel 104 (e.g., via opening 110). If sealing is required or desired, a seal may be added in one of multiple different ways. In some examples, the seal may be pre-installed and/or integrally molded with the fastener 112, which allows an over-molded seal to be integrally molded to a fastener 112 and delivered to a customer as a PIA.

FIGS. 8a through 8c illustrate example pass-through doghouse-based fastening systems 100 d configured with a seal assembly 800. Specifically, FIGS. 8a and 8b illustrate, respectively, perspective and bottom plan views of the fastener 112 with a seal assembly 800, while FIG. 8c illustrates a side view of the fastener 112 with the seal assembly 800 assembled with the first and second panels 102, 104. To better illustrate placement of the seal 802, the right-hand portion of FIG. 8c is illustrated as a cross-sectional view.

The seal assembly 800 generally comprises a seal 802 and a seal carrier 804. The seal carrier 804 is connected to the fastener 112 by way of a transitory connection 806. In some examples, the fastener 112 is molded as a single component with the seal carrier 804 connected to the fastener 112 by way of the transitory connection 806. In other examples, the fastener 112 and the seal carrier 804 are fabricated separately and connected by way of the transitory connection 806. The seal carrier 804 is configured to transition from an initial position to a deployed position by breaking the transitory connection 806.

In one example, the seal carrier 804 is connected to the fastener 112 by way of a transitory connection 806 at the collar 214. In another example, the seal carrier 804 is connected to the fastener 112 by way of a transitory connection 806 at the neck 212. The transitory connection 806 may be, for example, one or more of a frangible connection (e.g., a thin, breakable features, such as tethers and flash-gates), a mechanical coupling (e.g., snaps, clips, etc.), an adhesive, or any other suitable connection or coupling mechanism. As illustrated, the seal assembly 800 is sized to surround the doghouse structure 106 when assembled between the first and second panels 102, 104.

The seal 802 may be fabricated from a foam material, thermoplastic, rubber, etc. Example thermoplastics include, inter alia, polyethene (PE), polyvinyl chloride (PVC), etc. In some examples, the seal 802 is over-molded onto the seal carrier 804 to form the seal assembly 800. Therefore, in some examples, the wherein the seal carrier 804 is a rigid plastic structure and the seal 802 is over-molded onto the seal carrier 804. The seal carrier 804 may be configured to engage and/or clip onto the fastener 112 or doghouse structure 106. With reference to FIG. 8a , the fastener 112 may be provided with the seal 802 and the seal carrier 804 positioned at a temporary location (e.g., at or near the collar 214 or an end of the neck 212 opposite the head assembly 210). Once the fastener 112 is inserted into the doghouse structure 106, the seal 802 and the seal carrier 804 may be slid over the fastener 112, breaking the transitory connection 806, and toward the head assembly 210 (e.g., toward the doghouse structure 106) as indicated by arrow 808. Once the seal assembly 800 is in place, the fastener 112 may be inserted through the opening 110 of the second panel 104, after which, the seal 802 and seal carrier 804 becomes sandwiched between the first and second panels 102, 104 to seal the opening 110.

FIGS. 9a through 9f illustrate perspective assembly views of the pass-through doghouse-based fastening system with a seal assembly during assembly in accordance with an aspect of this disclosure. FIG. 9a illustrates a fastener 112 with a seal assembly 800 coupled thereto via a transitory connection 806. As illustrated in FIGS. 9b and 9c , the head assembly 210 of the fastener 112 is slid laterally across a surface of the first panel 102 into the chamber 218 until fastener 112 stops (e.g., against a wall) or is otherwise aligned between the doghouse sidewalls 220. The first panel 102 and the second panel 104 may be planar or curved. For example, the first panel 102 may be shaped to define a first surface profile and the second panel 104 may shaped to define a second surface profile that compliments or otherwise corresponds to the first surface profile.

The seal assembly 800 is separated from its temporary initial position on the fastener 112 using force. That force breaks or otherwise separates the transitory connection 806, making the seal assembly 800 independent from the fastener 112. The force can be exerted by hand, through the use of a tool, by pressing the second panel 104 against the seal assembly 800, or through any other suitable manner.

With reference to FIG. 9d , the seal assembly 800 is pushed onto the fastener 112 and into its final deployed position (e.g., around the doghouse structure 106). In some examples, the fastener 112 or the doghouse structure 106 may be designed to secure the seal assembly 800 in its deployed position using, for example, clips, snaps, press fit, etc. The fastener 112, now a PIA component 900 with the first panel 102 and the seal assembly 800, may be shipped to a customer (e.g., an OEM). The OEM may then assemble the PIA component 900 with a second panel (e.g., a vehicle panel) via all the fasteners 112 coupled thereto as illustrated in FIGS. 9e and 9 f.

As can be appreciated, the assembly steps illustrated in FIGS. 9a through 9f may be performed by one or more entities. In some examples, as best illustrated in FIGS. 9a through 9 d, the seal assembly 800 can installed to the fastener 112 and doghouse structure 106 as a PIA (e.g., by a Tier supplier) prior to shipment to the customer (e.g., an OEM). In such cases, the customer can then install the PIA to the second panel 104 as best illustrated in FIGS. 9e and 9f . In some examples, the seal assembly 800 could be left in the position illustrated in FIG. 9c and later installed by using force exerted during final assembly by the second panel 104 (e.g., effectively omitting the step illustrated in FIG. 9d ). However, there exists is a risk of the seal assembly 800 being knocked off the fastener 112 or the fastener 112 falling out of the doghouse structure 106 during transit to a customer. Therefore, installing the seal assembly 800 after the fastener 112 is placed in the doghouse structure 106 as illustrated in FIG. 9d prior to transit to the next assembly step can be advantageous. This would also enable the operator to confirm that the seal assembly 800 is seated properly. Further, with the seal assembly 800 protected by the fastener 112 and the doghouse structure 106, it is much less likely to be dislodged prior to final assembly.

FIG. 10 is a flowchart representative of an example method 1000 of forming a sealed blind connection between a first panel 102 and a second panel 104 via a doghouse structure 106 and a fastener 112 that has a head assembly 210 and a seal assembly 800. At step 1002, the head assembly 210 slides across a surface of the first panel 102 into a chamber 218 of the doghouse structure 106. At step 1004, the seal assembly 800 slides or otherwise transitions from an initial position to a deployed position. The seal assembly 800 comprises a seal 802 and a seal carrier 804. In some examples, the initial position is at or adjacent the collar 214 of the fastener 112 and the deployed position is at or adjacent the head assembly 210. In some examples, the seal 802 is over-molded onto the seal carrier 804. The seal carrier 804 may be coupled to the fastener 112 in the initial position via a transitory connection 806. For example, the transitory connection 806 is a flash-gate formed during a plastic injection process. At step 1006, a portion of the fastener 112 e.g., the neck 212, the collar 214, or portion thereof passes through an opening 110 formed on the second panel 104.

FIG. 11 is a flowchart representative of an example method 1100 of manufacturing a fastening system. At step 1102, a fastener 112 is formed via a plastic injection process, wherein the fastener 112 defines a head assembly 210, a neck 212, and a seal carrier 804. The seal carrier 804 is coupled to the neck 212 by a transitory connection 806. For example, the transitory connection 806 is a flash-gate formed during a plastic injection process. In some examples, the seal carrier 804 is coupled directly to the neck 212 or coupled to the neck 212 via a collar 214. The seal carrier 804 is configured to separate from the neck 212 or the collar 214 via the transitory connection 806 and to deploy to the head assembly 210. At step 1104, a seal 802 is over-molded on to the seal carrier 804.

While the present method and/or system has been described with reference to certain implementations, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present method and/or system. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. For example, block and/or components of disclosed examples may be combined, divided, re-arranged, and/or otherwise modified. Therefore, the present method and/or system are not limited to the particular implementations disclosed. Instead, the present method and/or system will include all implementations falling within the scope of the appended claims, both literally and under the doctrine of equivalents. 

1. A fastening system for forming a sealed blind connection between a first panel and a second panel, the fastening system comprising: a fastener configured to retain the second panel via an opening formed in the second panel, wherein the fastener comprises a head assembly configured to engage a doghouse structure positioned on the first panel; and a seal assembly having a seal and a seal carrier, wherein the seal carrier is coupled to the fastener via a transitory connection.
 2. The fastening system of claim 1, wherein the transitory connection is an adhesive.
 3. The fastening system of claim 1, wherein the transitory connection is a frangible connection.
 4. The fastening system of claim 1, wherein the transitory connection is a mechanical coupling.
 5. The fastening system of claim 1, wherein the fastener and the seal carrier are fabricated as a single component.
 6. The fastening system of claim 5, wherein the fastener and the seal carrier are fabricated via a plastic injection process.
 7. The fastening system of claim 6, wherein the transitory connection is a flash-gate formed during the plastic injection process.
 8. The fastening system of claim 1, wherein the seal carrier is a rigid plastic structure and the seal is over-molded onto the seal carrier.
 9. The fastening system of claim 1, wherein the seal carrier is configured to transition from an initial position to a deployed position by breaking the transitory connection.
 10. The fastening system of claim 9, wherein the seal carrier is configured to engage a feature of the fastener to secure the seal carrier in the deployed position.
 11. The fastening system of claim 9, wherein the seal carrier is configured to surround the doghouse structure when in the deployed position.
 12. The fastening system of claim 1, wherein the doghouse structure is configured to pass at least partially through the opening.
 13. A method of forming a sealed blind connection between a first panel and a second panel via a doghouse structure and a fastener that has a head assembly and a seal assembly, the method comprising: sliding the head assembly across a surface of the first panel into a chamber of the doghouse structure; sliding the seal assembly from an initial position to a deployed position, wherein the seal assembly comprises a seal and a seal carrier; and passing a portion of the fastener through an opening formed on the second panel.
 14. The method of claim 13, wherein the initial position is at or adjacent a collar of the fastener and the deployed position is at or adjacent the head assembly.
 15. The method of claim 13, wherein the seal carrier is coupled to the fastener in the initial position via a transitory connection.
 16. The method of claim 15, wherein the transitory connection is a flash-gate formed during a plastic injection process.
 17. A method of manufacturing a fastening system, the method comprising: forming a fastener via a plastic injection process, wherein the fastener defines a head assembly, a neck, and a seal carrier, wherein the seal carrier is coupled to the neck by a transitory connection; and over-molding a seal on to the seal carrier.
 18. The method of claim 17, wherein the transitory connection is a flash-gate formed during the plastic injection process.
 19. The method of claim 17, wherein the seal carrier is coupled to the neck via a collar.
 20. The method of claim 17, wherein the seal carrier is configured to separate from the neck via the transitory connection and to deploy to the head assembly. 